{"id":667,"date":"2021-09-30T07:36:15","date_gmt":"2021-09-30T07:36:15","guid":{"rendered":"https:\/\/dev.ikonixasia.com\/ar\/2021\/09\/30\/in-the-race-for-a-reliable-and-safe-ev-battery\/"},"modified":"2022-12-28T03:08:08","modified_gmt":"2022-12-28T03:08:08","slug":"in-the-race-for-a-reliable-and-safe-ev-battery","status":"publish","type":"post","link":"https:\/\/www.ikonixasia.com\/ar\/in-the-race-for-a-reliable-and-safe-ev-battery\/","title":{"rendered":"In the Race for A Reliable and Safe EV Battery"},"content":{"rendered":"<div id=\"pl-25613\"  class=\"panel-layout\" >\n<div id=\"pg-25613-0\"  class=\"panel-grid panel-no-style\" >\n<div id=\"pgc-25613-0-0\"  class=\"panel-grid-cell\"  data-weight=\"1\" >\n<div id=\"panel-25613-0-0-0\" class=\"so-panel widget widget_sow-editor panel-first-child panel-last-child\" data-index=\"0\" data-style=\"{&quot;background_image_attachment&quot;:false,&quot;background_display&quot;:&quot;tile&quot;,&quot;background_image_size&quot;:&quot;full&quot;}\" >\n<div\n\t\t\t\n\t\t\tclass=\"so-widget-sow-editor so-widget-sow-editor-base\"\n\t\t\t\n\t\t><\/p>\n<div class=\"siteorigin-widget-tinymce textwidget\">\n\tWith the electric vehicle (EV) flourishing in the automobile industry, the race of developing a better battery is the key to win the current competition. Every automaker increases the batteries production to meet the demand for new orders and replacements. Tesla has actively built a battery-manufacturing \u2018Megafactory\u2019 to supply enough batteries. Toyota also announced to invest in battery development and expand ten more production lines by 2025. However, the battery evolvement is not only focusing on storage and energy but reliability and safety are equally important. Therefore, each battery must pass a series of electrical safety tests to ensure its safety and compliance before going to market.<\/p>\n<p><img fetchpriority=\"high\" fetchpriority=\"high\" decoding=\"async\" class=\"wp-image-35263 aligncenter\" src=\"https:\/\/www.ikonixasia.com\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_image_1.webp\" alt=\"\" width=\"393\" height=\"393\" srcset=\"https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_image_1.webp 500w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_image_1-300x300.webp 300w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_image_1-150x150.webp 150w\" sizes=\"(max-width: 393px) 100vw, 393px\" \/><\/p>\n<p><strong>EV Battery Relevant Standards <\/strong><\/p>\n<p>Batteries are series-parallel connected to increase the voltage up to 300V on the battery pack to enhance endurance. This is much higher than the Safety Extra Low Voltage (SELV, &lt; 60Vdc), so the battery pack&#8217;s electrical safety needs additional attention.<\/p>\n<p><img decoding=\"async\" class=\"size-full wp-image-35265 aligncenter\" src=\"https:\/\/www.ikonixasia.com\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_image_2.webp\" alt=\"\" width=\"2560\" height=\"2086\" srcset=\"https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_image_2.webp 613w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_image_2-300x245.webp 300w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_image_2-100x80.webp 100w\" sizes=\"(max-width: 2560px) 100vw, 2560px\" \/><\/p>\n<p>A battery pack is composed of several battery modules, and each battery module is composed of several cells. If the battery modules and cells have any defaults, it may damage the battery pack and have potential safety concerns. Therefore, most manufacturers conduct insulation resistance (IR) tests on the cells to ensure no foreign particles and damage in the inner insulation layer. Follow by the Hipot test between the battery module\u2019s terminals and the chassis to ensure the assembly and structure are safe.<\/p>\n<p>The complete battery pack must pass the UL 2580 electrical safety test. The following are electrical safety test criteria:<\/p>\n<ul>\n<li>IR test<\/li>\n<\/ul>\n<p>If the insulation capability is inadequate, insulation failure may occur to damage the battery. Therefore, use the maximum working voltage (usually 300Vdc to 600Vdc) to conduct the IR tests for 60 seconds. The IR value must be greater than 100 ohms\/Vdc (usually 30000 ohms to 60000 ohms in total).<\/p>\n<ul>\n<li>Hipot Test<br \/>\nBy ensure the battery packs\u2019 structure and assembles properly can avoid insulation failure occurs. So, conduct the Hipot test with twice rated DC voltage (usually 600 Vdc to 1200Vdc) for 60 seconds. After the test, the DUT should not breakdown.<\/li>\n<\/ul>\n<p>The testing methods show in the following diagram. The testing voltage applies in turns to the battery\u2019s terminals and the return lead connect chassis.<\/p>\n<p><img decoding=\"async\" class=\"alignleft wp-image-35255 size-full\" src=\"https:\/\/www.ikonixasia.com\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_1_en.webp\" alt=\"\" width=\"1280\" height=\"505\" srcset=\"https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_1_en.webp 1280w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_1_en-300x118.webp 300w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_1_en-1024x404.webp 1024w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_1_en-768x303.webp 768w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_1_en-800x316.webp 800w\" sizes=\"(max-width: 1280px) 100vw, 1280px\" \/><\/p>\n<p>Figure 1: UL 2580 EV Battery Pack Safety Testing Configuration<\/p>\n<p>In China, the EV battery pack must comply with GB 38031 to conduct the IR test. Apply a large DC voltage to terminals in turn, and measure the IR value between terminals and chassi. The test method shows in Figure 2. The testing voltage is 500Vdc or 1.5 times rated voltage (usually up to 900Vdc) for 60 seconds. The testing result should be greater than 100 ohm\/V (normally around 30000 ohms to 60000 ohms).<\/p>\n<p><img loading=\"lazy\" loading=\"lazy\" decoding=\"async\" class=\"alignleft wp-image-35259 size-full\" src=\"https:\/\/www.ikonixasia.com\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_2_en.webp\" alt=\"\" width=\"1280\" height=\"518\" srcset=\"https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_2_en.webp 1280w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_2_en-300x121.webp 300w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_2_en-1024x414.webp 1024w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_2_en-768x311.webp 768w, https:\/\/www.ikonixasia.com\/ar\/wp-content\/uploads\/sites\/2\/2022\/12\/issue21_figure_2_en-800x324.webp 800w\" sizes=\"auto, (max-width: 1280px) 100vw, 1280px\" \/><\/p>\n<p>Figure 2: GB 38031 EV Battery Pack Safety Testing Configuration<\/p>\n<p><strong>Ikonix Offers Completed Test Solutions<\/strong><\/p>\n<p>For the electrical safety testing of the EV batteries, legendary SE Series Electrical Safety Analyzer is your best choices. SE series have AC\/DC Hipot and IR test functions. The maximum output can reach 500 VA which meets the UL\u2019s safety tests\u2019 requirements. Along with the battery packs\u2019 voltage continually increase, the SE series provides up to 5kVac and 6kVdc for the Hipot test and 6kVdc for IR tests to meet the R&amp;D and labs\u2019 needs.<\/p>\n<p>The EV era is evolving. Ikonix works closely with industry-leading companies to help the development and safety of EVs. With more than 80 years of safety testing industry experience, we provide complete testing solutions for automakers and manufacturers. If you want to learn more about the EV industry solutions, <a href=\"https:\/\/www.ikonixasia.com\/2021\/05\/04\/ul-1004-1-electrical-motor-safety-testing-standard\/\" target=\"\u201d_blank\u201d\" rel=\"noopener\">issue 16<\/a> and <a href=\"https:\/\/www.ikonixasia.com\/2021\/07\/29\/electrical-vehicle-charging-station-iec-61851-and-iec-62196-ensure-for-the-ultimate-electrical-safety\/\" target=\"\u201d_blank\u201d\" rel=\"noopener\">19<\/a> has more testing information of motor and charging stations. Or you can contact our sales representatives to learn the complete solution now.<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>With the electric vehicle (EV) flourishing in the automobile industry, the race of developing a better battery is the key to win the current competition. Every automaker increases the batteries production to meet the demand for new orders and replacements. Tesla has actively built a battery-manufacturing \u2018Megafactory\u2019 to supply enough batteries. Toyota also announced to &hellip;<\/p>\n","protected":false},"author":1,"featured_media":32113,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[33],"tags":[],"solutions":[],"application":[],"standard":[],"class_list":{"0":"post-667","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-enewsletter"},"acf":[],"_links":{"self":[{"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/posts\/667","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/comments?post=667"}],"version-history":[{"count":0,"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/posts\/667\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/"}],"wp:attachment":[{"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/media?parent=667"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/categories?post=667"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/tags?post=667"},{"taxonomy":"solutions","embeddable":true,"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/solutions?post=667"},{"taxonomy":"application","embeddable":true,"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/application?post=667"},{"taxonomy":"standard","embeddable":true,"href":"https:\/\/www.ikonixasia.com\/ar\/wp-json\/wp\/v2\/standard?post=667"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}